Fertilizers containing animal nutrient core packet

ABSTRACT

A fertilizer supplying animal nutrients including a core particle having an outer surface and comprising compounds containing animal nutrients, and a coating of urea on the outer surface of the core particle, and further a process of making the fertilizer including the steps of: screening animal nutrient core particles comprising a powdered substance containing an animal nutrient, to a preselected particle size; spraying melted urea onto the surface of the nutrient core particles to produce a coating on the nutrient core particles; granulating the nutrient core particles with sprayed melted urea to produce nutrient core granules; and cooling the nutrient core granules.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Ser. No. 15/601,378 filed 22May 2017, which is a continuation of U.S. Ser. No. 14/135,112 filed 19Dec. 2013, which is a continuation of U.S. Ser. No. 13/007,492 filed 14Jan. 2011, which claims benefit of U.S. provisional application No.61/295,461 filed 15 Jan. 2010. The contents of the above patentapplications are incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

This invention relates to fertilizer compositions that have beendeveloped to increase nutrients required by humans and/or domesticatedanimals in food plants, which is easily tailored for application toparticular agricultural land, deficient in specific human/domesticatedanimal nutrients. In this respect, the invention is a delivery systemthat can be easily adjusted to deliver human/domesticated animalnutrients that have been determined to be deficient, in a determinedappropriate amount to increase the amount of the nutrients in foodplants in order to alleviate or eliminate the deficiency in thehuman/domesticated animal diet. The compositions include plant growthfertilizers that promote plant growth in addition to the deliveredhuman/domesticated animal nutrients.

Additionally, the invention includes processes of making the fertilizercompositions containing animal nutrients.

The invention further includes methods of alleviating or eliminatingdeficiencies in animal nutrients by means of increasing the amounts ofthe nutrients in food plants.

On a worldwide basis, the demand for the present fertilizer containinganimal nutrients is tremendous, as emphasized in the following excerptsregarding deficiencies of iodine, iron, zinc and vitamin A, from theWorld Health Organization, World Health Report 2002.

Iodine deficiency has been associated with mental retardation and braindamage, lower mean birth weight and increased infant mortality, hearingimpairment, impaired motor skills, and neurological dysfunction. Over2.2 billion people in the world may be at risk for iodine deficiency,and estimates suggest over one billion experience some degree of goiter.Globally, iodine deficiency disorders were estimated to result in 2.5million Disability Adjusted Life Years (“DAYLs,” i.e., the sum of yearsof potential life lost due to premature mortality and the years ofproductive life lost due to disability) which is 0.2% of total globalDAYLs. Approximately 25% of this burden occurred in Africa, 17% inSouth-East Asia and 16% in the Eastern Mediterranean.

Iron deficiency is one of the most prevalent nutrient deficiencies inthe world, affecting an estimated two billion people. Young children andpregnant and postpartum women are the most commonly and severelyaffected because of the high iron demands of infant growth andpregnancy. Iron deficiency may, however, occur throughout the life spanwhere diets are based mostly on staple foods with little meat intake orpeople are exposed to infections that cause blood loss (primarilyhookworm disease and urinary schistosomiasis). About one-fifth ofprenatal mortality and one-tenth of maternal mortality in developingcountries is attributable to iron deficiency. There is also a growingbody of evidence indicating that iron deficiency anemia in earlychildhood reduces intelligence in mid-childhood. There is also evidencethat iron deficiency decreases fitness and aerobic work capacity throughmechanisms that include oxygen transport and respiratory efficiencywithin the muscle. In total, 0.8 million (1.5%) of deaths worldwide areattributable to iron deficiency, 1.3% of all male deaths and 1.8% of allfemale deaths. Attributable DALYs are even greater, amounting to theloss of about 35 million healthy life years (2.4% of global DALYs). Ofthese DALYs, 12.5 million (36%) occurred in South-East Asia, 4.3 million(12.4%) in the Western Pacific, and 10.1 million (29%) in Africa.

Zinc deficiency is largely related to inadequate intake or absorption ofzinc from the diet. Zinc requirements for dietary intake are adjustedupward for populations in which animal products (the best sources ofzinc) are limited, and in which plant sources of zinc are high inphytates (strong chelators). It is estimated that zinc deficiencyaffects about one-third of the world's population, with estimatesranging from 4% to 73% across regions. Mild to moderate zinc deficiencyis quite common throughout the world. Worldwide, zinc deficiency isresponsible for approximately 16% of lower respiratory tract infections,18% of malaria and 10% of diarrheal disease. The highest attributablefractions for lower respiratory tract infection occurred in Africa, theAmericans, the Eastern Mediterranean and South-East Asia (18-22%);likewise, the attributable fractions for diarrheal diseases were high inthese four regions (11-13%). Attributable fractions for malaria werehighest in Africa and the Eastern Mediterranean (10-22%). In total, 1.4%(0.8 million) of deaths worldwide were attributable to zinc deficiency:1.4% in males and 1.5% in females. Attributable DALYs were higher, withzinc deficiency accounting for about 2.9% of worldwide loss of healthylife years. Of this disease burden, amounting to 28 million DALYsworldwide, 34.2% occurred in South-East Asia, and 49.1% in Africa.

Vitamin A is an essential nutrient required for maintaining eye healthand vision, growth, immune function, and survival. Severe vitamin Adeficiency can be identified by the classic eye signs of xerophthalmia,such as corneal lesions. Milder vitamin A deficiency is far more common.Vitamin A deficiency causes visual impairment in many parts of thedeveloping world and is the leading cause of acquired blindness inchildren. Children under five years of age and women of reproductive ageare at highest risk of this nutritional deficiency and its adversehealth consequences. Globally, approximately 21% of all children sufferfrom vitamin A deficiency (defined as low serum retinol concentrations),with the highest prevalence of deficiency, and the largest numberaffected in South-East Asia (78%) and in Africa (63%). There is asimilar pattern for women affected by night blindness during pregnancy,with a global prevalence of approximately 5% and the highest prevalenceamong women living in Asia and Africa where maternal mortality rates arealso high. It is estimated that vitamin A deficiency also caused about16% of worldwide burden resulting from malaria and 18% resulting fromdiarrheal diseases. Attributable fractions for both diseases were 16-20%in Africa. In South-East Asia, about 11% of malaria was attributed tovitamin A deficiency. About 10% of maternal DALYs worldwide wereattributed to vitamin A deficiency, again with the proportion highest inSouth-East Asia and Africa. Other outcomes potentially associated withvitamin A deficiency are fetal loss, low birth weight, preterm birth andinfant mortality. In total, about 0.8 million (1.4%) of deaths worldwideresult from vitamin A deficiency, 1.1% in males and 1.7% in females.Attributable DALYs are higher: 1.8% of global disease burden. Over 4-6%of all disease burden in Africa was estimated to result from vitamin Adeficiency.

Thus, much of the world's population is lacking in micronutrients andiodine, which can cause a variety of illness or death. This is generallya direct result of consuming food crops that were grown in micronutrientand/or iodine deficient soils. Primary micronutrients which may bedeficient include iron, zinc, copper, magnesium and selenium. Food cropsgrown in deficient soils not only have reduced crop yields, but alsohave low micronutrient and/or iodine content needed for human health.

A quick acting and cost effective method to alleviate this problem is touse enriched fertilizers containing micronutrients and/or iodine as wellas vitamins and other beneficial additives. These human nutrients aretransferred from the soil, through plant uptake, to the edible fruit,vegetable, seed, leaves, stalk or other portion of the food crop plant.Similarly, domesticated animals that have nutrient deficiencies willhave improved health and productively by consuming food plants that havereceived increased amounts of the deficient nutrients. Moreover, humanconsumption of the nutrient healthy animals will increase human health.The present invention employs a new and particularly effective means ofproviding selected types and amounts of animal nutrients to food cropsand concurrently providing plant nutrients for crop high yield.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed towards a new and entirely unexpectedfertilizer composition wherein a core particle is composed of selectedtypes and amounts of animal micronutrients, iodine and/or vitamins whichis coated with plant growth fertilizer, particularly urea as a nitrogenplant nutrient, but may also include other plant nutrients of, forexample, phosphorus and potassium. Thus, a combined animal nutrient andplant nutrient fertilizer may be tailored and applied to agriculturalareas to fulfill the specific needs of animal (particularly human) andfood plant (crop) nutrition. The core packet of selected animalnutrients may be produced with only a small coating of urea as anintermediate product for future processing or such intermediate productmay be further processed substantially in a continuous manner to thefinal fertilizer product. For convenience only, hereafter, nutrients forincreased health of humans and domestic animals will be referred to ashuman nutrients and nutrients for increased food plant will be referredto as plant nutrients.

The physical structure of the present fertilizer product is novel andthe process of the present invention that was developed for making theproduct, including the nutrient core packet and one or more coatings,includes novel granulation steps.

The present invention further includes a method of deliveringhuman/domesticated animal nutrients that have been determined to bedeficient, in a determined appropriate amount to increase the amount ofthe nutrients in crops, in order to alleviate or eliminate thedeficiency in the human/domesticated animal diet.

DETAILED DESCRIPTION OF THE INVENTION

While in the manufacture of fertilizers, the granulation of urea isknown, the simple addition of micronutrients, iodine, or other essentialnutrients to a urea granulation process can potentially cause processingproblems such as agglomeration, dusting, excess moisture and lowproduction rate. Physical properties of the resulting urea granules canalso be affected such as reduced particle strength, dust formation,caking in storage, or more susceptibility to humidity. Further,additives, such as human nutrient compounds, can also be damaged fromthe high urea melt temperature (275 to 290 F).

The present invention particularly relates to a new delivery system forincorporating micronutrients and/or iodine or any other beneficialmaterials into fertilizers to provide highly effective availability ofthe nutrients to crop plants and uptake of the nutrients into the plant.The delivery system consists of a core packet comprised of animalnutrients (nutrients in the broad sense of substances in food that aidin healthy growth and health maintenance of animals). The core packetparticles are produced by granulating (e.g. drum granulation) thenutrient core ingredients, optionally with a binder (e.g., monoammoniumphosphate (MAP)). On a dry basis the binder is 0.3 to 0.9% by wt. andpreferably 0.5 to 0.7% by wt. The resulting core packet particle size isin the range of 0.7 mm to 1.5 mm and preferably in the range of 0.9 mmto 1.2 mm in diameter depending on the desired additive concentration.

The core particles are over coated with urea. This first coating of ureais to build up the particle size for improved processing by such meansas a high or even low flow fluid bed reactor to produce the fertilizerproduct granules. The size of core particles with the first coating ofurea is 0.9 to 1.5 mm and preferably 1.0 to 1.2 mm. The core particleswith urea overcoat is an intermediate product, which may be stored orprocessed substantially immediately to a final fertilizer granularproduct.

The core particles with first coating of urea are introduced to a ureagranulation process, to be coated a second time with urea and optionallyincluding other plant macronutrients such as phosphorus and potassium toyield the fertilizer granular product. The fertilizer granules eachcontain a core packet particle near the center of the granule. The finalproduct granule size ranges from 2.50 to 3.60 mm and preferably 2.5 to2.8 mm.

The urea employed in the coating may optionally be substituted orsupplemented with coating materials selected from the group consistingof ureaform, water soluble urea formaldehyde polymer, water insolubleurea formaldehyde polymer, methylene urea, methylene diurea,dimethylenetriurea and urea formaldehyde.

The plant macronutrient compounds include the following:

1) nitrogen compounds selected from the group consisting of urea,ammonia, ammonium nitrate, ammonium sulfate, calcium nitrate, diammoniumphosphate, monoammonium phosphate, potassium nitrate and sodium nitrate;

2) phosphorous compounds selected from the group consisting ofdiammonium phosphate, monoammonium phosphate, monopotassium phosphate,dipotassium phosphate, tetrapotassium pyrophosphate, and potassiummetaphosphate.

3) potassium compounds selected from the group consisting of potassiumchloride, potassium nitrate, potassium sulfate, monopotassium phosphate,dipotassium phosphate, tetrapotassium pyrophosphate, and potassiummetaphosphate.

The core packet particles may be manufactured as an intermediate productfor later coating with urea or a tailored urea-macronutrient formulationfor application to a specific agricultural area, worldwide. Thefertilizer product granules may optionally receive an outer coating of asubstance having reduced solubility or otherwise of slower degradationto provide a slow or controlled release of the fertilizer, e.g., sulfuror polymer coatings.

Micronutrient sources include iron sulfate, iron oxides, chelated iron,zinc sulfate, iron nitrate, zinc oxide, chelated zinc, copper oxide,copper sulfate, copper nitrate, magnesium nitrate, magnesium sulfate,magnesium oxide, selenium sulfate and selenium oxide. Iodine sourcesinclude potassium iodide or sodium iodide. The proportion of totalmicronutrients in the fertilizer product range from 0.01 to 10.0% by wt.and preferably range from 0.1 to 5.0% by wt. Core packet particlesprepared for regions that have iodine deficient soils typically contain0.01 to 5% by wt. iodine, and more preferably contain 0.01 to 1.0% bywt. Core packet particles typically contain 0.01 to 10% wt. zinc andmore preferably 0.01 to 5% wt. zinc. Core packet particle typicallycontain 0.01 to 10% wt iron and more preferably contain 0.01 to 4% wt.iron.

Core packet particles may also include a vitamin-mineral composition toalleviate or eliminate human vitamin deficiencies. One or more vitaminsare selected from such vitamins as vitamins A, C, D, E and K, thiamin,riboflavin, niacin, vitamin B6 and B12, folic acid (vitamin B9),pantothenic acid (vitamin B5) and biotin (vitamin B7). In addition tothe previously disclosed mineral nutrients of iron, zinc and iodineadditional mineral nutrients are selected from calcium, phosphorus,magnesium, selenium, copper, manganese, chromium, molybdenum, chloride,potassium, boron, nickel, silicon, tin, vanadium, and carotenoids suchas lutien, and lycopene.

See Table 1 for an exemplary list of components and exemplary amounts asmay constitute a complete human multivitamin.

TABLE 1 Vitamin-Mineral Composition “Equate ™ Complete Mutlivitamin”Supplement Facts Serving Size: 1 Tablet Amount Per Serving: % DV VitaminA (29% as Beta Carotene) 3500 I.U.  70% Vitamin C 90 mg 150% Vitamin D400 I.U. 100% Vitamin E 30 I.U. 100% Vitamin K 25 mcg  31% Thiamin(Vit.B1) 1.5 mg 100% Riboflavin(Vit. B2) 1.7 mg 100% Niacin 20 mg 100%Vitamin B6 2 mg 100% Folic Acid 500 mcg 125% Vitamin B12 6 mcg 100%Biotin 30 mcg  10% Pantothenic Acid 10 mg 100% Calcium 200 mg  20% Iron18 mg 100% Phosphorus 109 mg  11% Iodine 150 mcg 100% Magnesium 100 mg 25% Zinc 11 mg  73% Selenium 55 mcg  79% Copper 0.9 mg  45% Manganese2.3 mg 115% Chromium 35 mcg  29% Molybdenum 45 mcg  60% Chloride 72 mg 2% Potassium 80 mg  2% Boron 150 mcg ** Nickel 5 mcg ** Silicon 2 mg **Tin 10 mcg ** Vanadium 10 mcg ** Lutein ‡ (Tagetes erecta) (flower) 250mcg ** Lycopene 300 mcg ** ** Daily Value (DV) not established. OtherIngredients: Dicalcium Phosphate, Magnesium Oxide, Potassium Chloride,Calcium Carbonate, Cellulose, Ascorbic Acid, Ferrous Fumarate, CornStarch, di-AlphaTocopheryl Acetate, Niacinamide, Polyvinyl Alcohol,Gelatin, Croscarmellose Sodium, d-Calcium Pantothenate, Crospovidone,Zinc Oxide, Magnesium Stearate, Titanium Dioxide, Polyethylene Glycol,Talc, Manganese Sulfate, Silicon Dioxide, Acacia, Maltodextrin,Hypromellose, Pyridoxine Hydrocholride, Glucose, CupricSulfate,Riboflavin, ThiamineMononitrate, VitaminAAcetate, BoricAcid, Sucrose,Folic Acid, Beta Carotene, Yellow 6 Lake, Chromium, Picolinate Lycopene,Lutein, Potassium Iodide, Sodium Selenate, Sodium Molydate, TricalciumPhosphate, Sodium Asorbate, Tocopherols, Red 40 Lake, Phytonadione,Biotin, Sodium Metavanadate, Nickelous Sulfate, Stannous Chloride,Cholecalciferol, Cyanocobalamin, Ascorbyl Palmitate

There is substantial flexibility in the manufacture of the core packetsto specifically tailor products to be produced for differentagricultural areas of the world, which have varying soil and weatherconditions. The present fertilizer products containing nutrient corepackets can be produced by a number of typical fertilizer manufacturingprocesses including fluid bed granulation, drum granulation, and pangranulation. While the unit operations comprise typical fertilizermanufacturing processes, the combination of operations is novel toproduce the product of the present invention.

The micronutrient core packet particles are primarily formed bygranulating a fine powder (or fine crystals) of various micronutrientsand/or iodine using a binder such as corn syrup (e.g., 20-30% fructoseor 3-9% dry basis), other sugars (such as sucrose), starches,lignosulfonates (such as calcium or potassium or ammoniumlignosulfonates), PVA (polyvinyl acetate), methyl cellulose, MAP(monoammonium phosphate) and any other binders commonly used forgranulation. Binder content ranges from 1 to 10% by wt. and preferablyranges from 3 to 6% by wt. The granulation method for preparing the corepackets is selected from commonly used techniques such asdrumgranulation, pan granulation, pin-mixer, extrusion, compaction,fluid bed granulation and prilling. The core packet particles arepre-coated by processes for example of drum granulation, pan granulationor fluid bed granulation, with a small amount of urea (5 to 25% by wt.)to give the particle a sufficient size to be further processed,immediately or later in a urea production facility (by such means asdrum granulation, pan granulation or fluid bed granulation), to preventparticle damage or entrainment in a process air stream causing removalfrom the granulator.

If the raw material for the nutrient compound is in (fine) powder form,then granulation is required in order to increase the nutrient coreparticle size to the desired size before coating with urea.Alternatively, if the raw nutrient material is in a larger form, e.g.crystals, then granulation is not necessary and the raw nutrientmaterial is only screened to result in the desired nutrient coreparticle size.

The resulting nutrient core particles are then sprayed with melted ureaand granulated to result in a granulated nutrient core fertilizer finalproduct or intermediate product. If an intermediate product, a secondcoating of urea is sprayed on the intermediate granules, followed byfurther granulation to the final twice coated product. In both cases,after spraying with melted urea and granulation, the resulting granulesare cooled. In a commercial process, the granules would be cooled in afluid bed cooler.

EXAMPLES

Samples of the product of the present application were generally madeemploying the following protocol.

Samples of fertilizer granular products were produced comprised of corepacket particles composed of a binder and compounds containing thedesired nutrients with over-coatings of urea. For one exemplary example,for core packet particles, the binder is mono-ammonium phosphate (MAP)and/or corn syrup, and human nutrients are potassium iodide, zincsulfate, iron sulfate and a vitamin-mineral composition.

The core packet particles were produced by granulating powdered nutrientcompounds (and optionally other nutrient constituents) with the binderto form the core packet particles which were then screened to a specificsize or range of sizes.

Alternatively, the particles of single powdered nutrient compound (orother nutrient constituent) were not granulated but were instead onlyscreened to select a specific size or range of sizes to be the corepacketparticles.

Whether produced by granulation with subsequent screening or resultingfrom only screening, the core packet particles were over-coated withurea.

Industrial grade urea was melted and sprayed to overcoat the core packetparticles. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum toassist in forming a falling curtain during melt spray granulation. Thesame type of drum was used to make the core packet particles except thatthe drum contained no flights. The stainless steel granulation drum wasmounted on a variable speed base.

Approximately 1 pound of core packet particles was placed inside thedrum to form a falling curtain. The drum speed during granulation was35-40 rpm. The sample fertilizer granules were produced by this process.After granulation, the granules were allowed to cool.

Product samples were made with the constituents and amounts shown inTable 2. The samples are designated by product number NP3-16. Note thatthese samples were all produced based on the volume of the final productgranule. For exemplary purposes the desired final product size was amean particle size of 2.80 mm. With this product size fixed the nutrientcore size was adjusted to vary the iron, zinc, and iodine content. Inexamples employing iron, zinc or iodine, the compound was screened orgranulated and then screened, and then the iron, zinc or iodine contentwas determined by volume of the nutrient core in relation to the finalproduct size. This resulted in amounts of constituents in the samplecompositions to be stated on a percent weight basis, estimatedplus/minus 10-15%.

While the samples of the Examples were produced in this manner, on afull scale production basis the nutrient cores would be screened orgranulated and then screened just as in the examples, but the coreswould be metered in the process on a percent weight basis.

The following are examples, representative of making product samples.

Example 1. (Product NP-3, NP-4, and NP-5)

Samples were produced containing 1, 3, and 5% iron from iron sulfatecore packet. Iron sulfate crystals were screened to a pre-determinedsize prior to being over-coated with urea. Sample NP-3 contained 5% ironwas produced by screening the iron sulfate crystals to 1.7 to 2.0 mm.Sample NP-4 contained 3% iron was produced by screening the iron sulfatecrystals to 1.4 to 1.7 mm.

Sample NP-5 contained 1% iron was produced by screening the iron sulfatecrystals to 1.0 to 1.2 mm.

Approximately 1 pound of each core material was placed inside the drumto form a falling curtain. The urea over-coating drum was 20″ indiameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″apart inside the drum to assist in forming a falling curtain during meltspray granulation. The stainless steel granulation drum was mounted on avariable speed base. The drum speed during granulation was 35-40 rpm.Industrial grade urea was melted and sprayed to overcoat the core packetand produce a final product size of 2.8 mm.

Example 2. (NP-6)

A sample was produced containing 1% iron from an iron EDTA (ethylenediamine tetra acetic acid) core packet. Iron EDTA nutrient cores wereproduced by first granulating powdered iron EDTA with 6-7% corn syrup ina lab scale pan granulator. Sample NP-6 contained 1% iron that wasproduced by screening the granulated core to a particle size of 1.0 to1.4 mm.

Approximately 1 pound of nutrient core material was placed inside thedrum to form a falling curtain. The urea over-coating drum was 20″ indiameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″apart inside the drum to assist in forming a falling curtain during meltspray granulation. The stainless steel granulation drum was mounted on avariable speed base. The drum speed during granulation was 35-40 rpm.Industrial grade urea was melted and sprayed to overcoat the core packetand produce a final product size of 2.8 mm.

Example 3. (NP-7)

A sample was produced containing 1% zinc from a zinc EDTA core packet.Zinc EDTA nutrient cores were produced by first granulating powderedzinc EDTA with 6-7% corn syrup in a lab scale pan granulator. SampleNP-7 contained 1% zinc that was produced by screening the granulatedcore to a particle size of 1.0 to 1.4 mm.

Approximately 1 pound of core material was placed inside the drum toform a falling curtain. The urea over-coating drum was 20″ in diameter,5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart insidethe drum to assist in forming a falling curtain during melt spraygranulation. The stainless steel granulation drum was mounted on avariable speed base. The drum speed during granulation was 35-40 rpm.Industrial grade urea was melted and sprayed to overcoat the core packetand produce a final product size of 2.8 mm.

Example 4. (NP-8, NP-9, and NP-10)

Samples were produced containing 1, 3, and 5% zinc from zinc sulfatecore packet. Zinc sulfate nutrient cores were produced by firstgranulating powdered zinc sulfate with 6-7% corn syrup in a lab scalepan granulator. Sample NP-8 containing 5% zinc was produced by screeningthe granulated zinc sulfate to 1.4 to 1.7 mm. Sample NP-9 contained 3%zinc was produced by screening the granulated zinc sulfate to 1.2 to 1.4mm. Sample NP-10 contained 5% zinc was produced by screening thegranulated zinc sulfate to 0.7 to 1.0 mm.

Approximately 1 pound of each nutrient core material was placed insidethe drum to form a falling curtain. The urea over-coating drum was 20″in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″apart inside the drum to assist in forming a falling curtain during meltspray granulation. The stainless steel granulation drum was mounted on avariable speed base. The drum speed during granulation was 35-40 rpm.Industrial grade urea was melted and sprayed to overcoat the core packetand produce a final product size of 2.8 mm.

Example 5. (NP-11, NP-12, and NP-13)

Samples were produced containing 1, 3, and 5% iodine from potassiumiodide core packet. Potassium iodide crystals were screened to apre-determined size prior to being over-coated with urea. Sample NP-11contained 5% iodine was produced by screening the potassium iodidecrystals to 1.0 to 1.2 mm. Sample NP-12 contained 3% iodine was producedby screening the potassium iodide crystals to 0.8 to 1.0 mm. SampleNP-13 contained 1% iodine was produced by screening the potassium iodidecrystals to 0.6 to 0.7 mm.

Approximately 1 pound of each nutrient core material was placed insidethe drum to form a falling curtain. The urea over-coating drum was 20″in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″apart inside the drum to assist in forming a falling curtain during meltspray granulation. The stainless steel granulation drum was mounted on avariable speed base. The drum speed during granulation was 35-40 rpm.Industrial grade urea was melted and sprayed to overcoat the core packetand produce a final product size of 2.8 mm.

TABLE 2 Product Examples of Nutrient Core Packet Nutrient CompositionNutrient Product# (%) Source Product Composition (%) NP 7 1% Zn ZincEDTA6.9% Zinc EDTA, 93.1% Urea NP 10 1% Zn Zinc Sulfate 2.8% Zinc Sulfate,97.2% Urea NP 9 3% Zn Zinc Sulfate 8.5% Zinc Sulfate, 91.5% Urea NP 8 5%Zn Zinc Sulfate 14.1% Zinc Sulfate, 85.9% Urea NP 6 1% Fe Iron EDTA 7.5%Iron EDTA, 92.5% Urea NP 5 1% Fe Iron Sulfate 5.0% Iron Sulfate, 95%Urea+ NP 4 3% Fe Iron Sulfate 10% Iron Sulfate, 90% Urea+ NP 3 5% FeIron Sulfate 15% Iron Sulfate, 85% Urea+ NP 13 1% I Potassium 1.3%Potassium Iodide, 98.7% Iodide Urea+ NP 12 3% I Potassium 3.9% PotassiumIodide, 96.1% Iodide Urea+ NP 11 5% I Potassium 6.5% Potassium Iodide,93.5% Iodide Urea+ NP 14 1% Vitamin Gel Capsules 90% Urea, 1% Vitamin A,9% A Inert NP 15 1% Zn, 1% Zinc Sulfate, 2.8% Zinc Sulfate, 5.0% Iron FeIron Sulfate Sulfate, 92.2% Urea NP 16 2% Zn, 2% Zinc Sulfate, 5.6% ZincSulfate, 10% Iron Fe Iron Sulfate Sulfate, 84.4% Urea Notes: 1)MAP—Monoammonium Phosphate 2) EDTA—ethylenediaminetetra acetic acid 3)Zn—Zinc 4) Fe—Iron 5) I—Iodine 6) B—Boron 7) N—Nitrogen 8) P—Phorphous+Binder of Corn Syrup was employed to granulate core constitutents

Example 6. Zinc Uptake in Spinach Plants from Application of FertilizerContaining Animal Nutrient Core Packet

In this example tests were performed to quantify the incorporation ofzinc in a common spinach variety (Bloomsdale Long-Standing) employingcompositions of the present invention. The tests quantified the increasein leaf zinc content due to application of compositions of the presentinvention containing zinc. The impact of the present compositions onspinach biomass increase was not the primary objective. In addition toapplications of the present compositions to soil, for comparativepurposes, foliar application of zinc solutions were applied to spinachleaves. Direct foliar applications provide an indication of potentiallymaximum amounts of zinc uptake into the leaves. A list of the sampleproducts of the present application is shown in Table 2.

Materials and Methods

1. Soil

-   -   8 kg Greenville loam (fine, kaolinitic, thermic Rhodie        Kandiudults), pH=6.2, organic matter=1.4%, CEC=5.2 cmol kg⁻¹.        The soil has been depleted of nutrients by previous cropping of        tomatoes and cabbage.

2. Experimental Units

-   -   The spinach was grown in 8-kg pots. Each pot was transplanted        with two spinach seedlings on Mar. 5, 2010

3. Blanket Fertilizer Rates—Basal

-   -   All fertilizer materials were laboratory grade reagents to avoid        contamination and antagonistic interaction with Zn, Fe and/or I.    -   Nitrogen: 250 mg N kg⁻¹ or 2 g N por⁻¹. All N was applied        basally and incorporated into the top 10 cm of the soil.    -   Phosphorus: 100 mg P kg⁻¹ or 0.8 g P por⁻¹ applied as        monocalcium phosphate (all basal and incorporated into the        entire 8 kg of soil).    -   Potassium: 415 mg K kg⁻¹ or 3.3 g K por⁻¹ applied as potassium        sulfate (all basal and incorporated into the entire 8 kg of        soil).    -   Magnesium: 30 mg Mg kg⁻¹ or 0.24 g Mg por⁻¹ applied as        MgSO₄.7H₂0 (all basal and incorporated into the entire 8 kg of        soil).    -   Calcium: Monocalcium phosphate (MCP) applied for P.    -   Sulfer: From sulfate of potash (SOP) and MgSO₄.    -   Micronutrients: As per treatment (see Table 3).

4. Basal Zn Fertilizer Rates

Zinc: 20 mg Zn kg⁻¹ or 0.16 g Zn por⁻¹ applied as ZnSO₄ 7 H₂0 solutionon topsoil just prior to transplanting for three treatments only (Table3).

5. Foliar Rates for Zn, Fe, I and Vitamin A

-   -   Foliar applications were used in treatments that have a foliar        component as indicated in Table 3.

6. Experimental Design

-   -   Randomized complete block with 40 treatments and three        replications for a total of 120 experimental units.

7. Crop Data Analysis

-   -   The fresh and dried weight of spinach leaves was determined and        analyzed for N, P, K, Zn, Fe and I.

TABLE 3 Treatment Description Basal Foliar Treatment Treatment N ProdSOP MCP MgSO₄ ZnSO₄ Zn KI Fe Vit A No. Description (g) (ppm) 1 Urea +5Zn 4.31 8 3.25 2.46 0.00 5 2 Urea + 10Zn 4.31 8 3.25 2.46 0.00 10 3Urea + 20Zn 4.31 8 3.25 2.46 0.00 20 4 Urea + 40Zn 4.31 8 3.25 2.46 0.0040 5 Urea + 60Zn 4.31 8 3.25 2.46 0.00 60 6 Urea + 10KI 4.31 8 3.25 2.460.00 10 7 Urea + 20KI 4.31 8 3.25 2.46 0.00 20 8 Urea + 30KI 4.31 8 3.252.46 0.00 30 9 Urea + 40KI 4.31 8 3.25 2.46 0.00 40 10 Urea + 100Fe 4.318 3.25 2.46 0.00 100 11 Urea + 300Fe 4.31 8 3.25 2.46 0.00 300 12 Urea +100 Vit A 4.31 8 3.25 2.46 0.00 100 13 Urea + 200 Vit A 4.31 8 3.25 2.460.00 200 14 Urea 4.31 8 3.25 2.46 0.00 0 0 0 0 15 NP3 4.77 8 3.25 2.460.00 16 NP4 4.88 8 3.25 2.46 0.00 17 NP5 4.74 8 3.25 2.46 0.00 18 NP64.82 8 3.25 2.46 0.00 19 NP7 4.74 8 3.25 2.46 0.00 20 NP8 4.95 8 3.252.46 0.00 21 NP9 4.72 8 3.25 2.46 0.00 22 NP10 4.61 8 3.25 2.46 0.00 23NP11 5.30 7.78 3.25 2.46 0.00 24 NP12 5.23 7.79 3.25 2.46 0.00 25 NP134.74 7.93 3.25 2.46 0.00 26 NP14 4.66 8.00 3.25 2.46 0.00 27 NP15 5.008.00 3.25 2.46 0.00 28 NP16 4.72 8.00 3.25 2.46 0.00 29 NP17 (void) 4.957.98 3.25 2.46 0.00 30 NP1 (void) 5.29 8.00 2.83 2.46 0.00 31 NP2 (void)4.91 7.97 2.94 2.46 0.00 32 NP4 + FOL 4.88 8 3.25 2.46 0.00 12.62 33NP6 + FOL 4.82 8 3.25 2.46 0.00 4.15 34 NP8 + FOL 4.95 8 3.25 2.46 0.0019.11 35 NP9 + FOL 4.72 8 3.25 2.46 0.00 9.98 36 NP12 + FOL 5.23 7.793.25 2.46 0.00 34.87 37 NP13 + FOL 4.74 7.93 3.25 2.46 0.00 11.61 38NP4 + 20 ppm Zn 4.88 8 3.25 2.46 0.70 39 NP12 + 20 ppm Zn 5.23 7.79 3.252.46 0.70 40 NP13 + 20 ppm Zn 4.74 7.93 3.25 2.46 0.70

Results and Discussion Zinc Response on Spinach Dry Matter Production

With Fe seed-core we had a poor response to Fe application in terms ofyield because The soil used for these tests had a sufficient amount ofiron and thus did not require any application of Fe fertilization. Theaddition of the iron product samples resulted in too much iron and had anegative impact on the spinach plants. The amount of iodine in theiodine product samples were too high and had a negative impact on thespinach plants. The types and amounts of nutrients in the products ofthe present invention can be adjusted to supply the amount of nutrientwithin the range of increasing nutrients within the plant and less thanthe inhibitory amount of nutrient. This experiment was not planned toprovide for such adjustment to initial soil nutrient content and spinachmaximum tolerance to the nutrient.

The positive results of the present zinc sample applications withspinach (spinach enrichment with zinc) shows that the present nutrientcore products supplies the needed nutrient to the crop when applieddirectly to the soil. The positive enrichment results of the zincproduct samples with spinach are representative of the validity of thepresent approach and would reasonably have a similarly positive resultusing iron, iodine and other nutrients based on soil characteristics andcrop plant requirements. Plants can be enriched with nutrient content(e.g. Zn content in spinach) employing the present nutrient corefertilizer products as long as application amounts do not have anegative impact on growth. Hence, there is no need to prove the nutrientcore products for each individual nutrient.

Due to the negative impact of I and Fe, particularly at higherapplication rates, the results for Zn sample application presented inTable 4 are for treatments without Fe and I. All foliar Znapplicationsled to a significant increase in spinach dry matter production (Table4). Soil application of Zn product samples was not as effective causingno significant (positive or negative) response on spinach dry matterproduction. However, the combination of soil application of productsamples and foliar applications of iron, zinc or iodine (see Table 3,Treatments 32-37) resulted in increased dry matter production. Thesamples NP 4, NP 12, and NP 13 contained iron or iodine products used inTreatments 38-40 and did not have any Zn. Accordingly, 20 ppm Zn wasapplied to the soil (basal), but the iron and iodine apparently had theaforementioned negative effect.

Since the soil used for this experiment was not deficient in Zn forplant growth, it was expected that soil application of Zn productsamples did not result in any significant response for dry matterproduction.

Zinc Fertilization Effect on Spinach Zn Concentration

There was a significant increase in the Zn concentration of spinach leafwith Zn application whether applied as foliar, soil applied productsamples or the combination of soil and foliar applications (Table 4).The spinach leaf Zn concentration without any Zn application was 42 ppm.Standard Zn concentration for spinach leaf is about 40-45 ppm. Based onthe leaf Zn concentration, the employed soil not Zn deficient, suppliedan adequate amount of Zn for spinach growth.

TABLE 4 Effect of Foliar and Soil Zn Application on Spinach Dry MatterProduction and Tissue Zn Content Total Dry Zn Method of MatterConcentration Applica- (g (% in- (% in- Treatment tion pot⁻¹) crease)(ppm) crease)  0 ppm Zn — 12.82 0 42.0 0  5 ppm Zn Foliar 16.70 30.3*121.5 189.4 10 ppm Zn Foliar 15.17 18.3* 195.8 366.2 20 ppm Zn Foliar15.14 18.1* 403.2 860.1 40 ppm Zn Foliar 15.19 18.5* 730.8 1,640.4 60ppm Zn Foliar 15.94 24.3* 1,067.3 2,441.9 NP7 (6.9% Zn EDTA) Soil 11.2−12.5 219.9 423.7 NP8 (14.1% ZnSO4) Soil 12.74 −0.6 188.9 349.9 NP9(8.5% ZnSO4) Soil 12.09 −5.7 147.8 252.0 NP10 (2.8% ZnSO4) Soil 13.061.9 98.4 134.4 NP8 + 19 ppm Zn Soil + 13.98 9.0 429.3 922.5 Foliar NP9 +10 ppm Zn Soil + 14.47 12.9* 258.4 515.4 Foliar *Significant differencein spinach dry weight. All Zn-fertilized spinach plants hadsignificantly higher tissue Zn concentration.

However, additional application of Zn (soil alone (product samples),foliar alone and combination of soil and foliar) resulted in Znenrichment of the spinach, with spinach concentration at two to 25 timeshigher than the standard. For example, at 60 ppm Zn foliar application,the spinach tissue Zn concentration was 1,067 ppm compared to 42 ppmwithout any Zn application. Soil application of Zn with Zn productsamples (NP 7-10) resulted in significant increases in tissue Znconcentration—from 2.3 to 5.2 times higher than with the control, zeroamount Zn treatment. As the concentration of Zn applied as ZnSO₄ in theZn product samples NP 10, 9, 8 increased (calculated as percent zinc:from 0.9% to 1.7% to 3.1%), the corresponding increase in leaf tissue Znconcentration was 98 ppm, 148 ppm and 189 ppm (Table 4). When the zincproduct sample NP 7 having Zn as Zn EDTA (calculated as 0.8% zinc), wasapplied, a resulting plant tissue Zn concentration of 220 ppm wasachieved. Zinc EDTA as the Zn source in the nutrient core for Zn productwas more effective than ZnSO₄ in increasing Zn tissue content in spinach(Table 4).

None of the treatments with Zn application alone resulted in asignificant decline in spinach dry matter. The high tissue Znconcentration resulting in this experiment was not at the expense ofreduced dry matter production.

Effect of Zinc Application on Zinc Uptake by Spinach

The positive effect of Zn application as foliar, soil or combination isreflected in the higher Zn uptake by spinach in all treatments comparedto the standard—0 ppm Zn treatment (Table 5). The results clearly showthat a common spinach variety can accumulate Zn without any negativeimpact on dry matter production but with potential nutritional andhealth benefits to humans. The nutrient core Zn product was an effectiveZn nutrient core fertilizer for soil application resulting in Znenriched plants.

TABLE 5 Effect of Zn Application as Foliar, on Soil or in Combination onZn Uptake by Spinach Method of Zn Uptake Treatment Application (mg/pot) 0 ppm Zn — 0.52  5 ppm Zn Foliar 2.02 10 ppm Zn Foliar 2.96 20 ppm ZnFoliar 6.11 40 ppm Zn Foliar 10.89 60 ppm Zn Foliar 17.74 NP7 (6.9% ZnEDTA) Soil 2.45 NP8 (14.1% ZnSO₄) Soil 2.33 NP9 (8.5% ZnSO4) Soil 1.77NP10 (2.8% ZnSO₄) Soil 1.25 NP8 + 19 ppm Zn Soil + Foliar 5.98 NP9 + 10ppm Zn Soil + Foliar 3.65 NP15 (2.8% ZnSO₄, 5% FeSO4) Soil 1.28

Table 5 also shows that due to Fe toxicity in the NP15 product, it waspossible to get a significantly higher Zn concentration, significantlylower dry matter and yet higher Zn uptake than with 0 ppm Zn treatment.However, such practice would not be commercially feasible (increasedcost due to micronutrient and with lower yield).

CONCLUSIONS

The results from this study, summarized in Table 4, clearly show thatboth application of the Zn core nutrient fertilizer products and Znfoliar application resulted in Zn enrichment of spinach.

Application the Zn core nutrient fertilizer products and Zn foliarapplication resulted in a several-fold increase in Zn concentration inspinach leaf and increased uptake of Zn compared to the standardtreatment (no Zn application), even though the soil was notZn-deficient. Zn foliar applications resulted in higher spinach growthand higher Zn content than soil application. For leafy vegetables, thegreater effectiveness with foliar application is expected.

However, for cereals, the effectiveness of foliar application may not beas great due to greater losses (leaf contact), cost of application andtranslocation of Zn from leaves to grains. Zn EDTA was more effectivethan ZnSO₄ as a Zn source in soil applied Zn nutrient core product.

While only a few exemplary embodiments of this invention have beendescribed in detail, those skilled in the art will recognize that thereare many possible variations and modifications which may be made in theexemplary embodiments while yet retaining many of the novel andadvantageous features of this invention. Accordingly, it is intendedthat the following claims cover all such modifications and variations.

1. A process to produce fertilizer product granules, comprising: a)providing core particles, wherein the core particles comprise corepackets that are coated with a first coating comprising urea; b)introducing the core particles into a urea granulation process; and c)spraying the core particles with a second coating comprising melted ureain said urea granulation process to yield granules.
 2. The process ofclaim 1, wherein the urea granulation process is carried out in a fluidbed.
 3. The process of claim 2, wherein said core particles have a sizeof 0.9 to 1.5 mm and wherein said step c) comprises increasing the sizeof the core particles to yield fertilizer granules with a size of 2.50to 3.60 mm.
 4. The process of claim 1, wherein the urea granulationprocess is carried out in a fluid bed granulator, and wherein step a)comprises: a1) providing core packets, and a2) spraying a coatingmaterial comprising melted urea onto the surface of the core packets toform the core particles in a granulation drum, wherein step b) comprisesintroducing the core particles into the fluid bed granulator.
 5. Theprocess of claim 1, wherein the second coating includes plantmacronutrients, wherein the plant macronutrients include phosphorus,potassium, or both.
 6. The process of claim 1, wherein the core packetscomprise at least one animal nutrient.
 7. A process to prepare aparticulate fertilizer for supplying animal nutrients to plants, saidprocess comprising: a) screening core particles comprising a powderedsubstance containing at least one animal nutrient to a preselectedparticle size; b) spraying melted urea onto the surface of thepreselected particles to produce a first urea coating thus obtainingonce-coated particles; c) granulating the once-coated particles toproduce once-coated granules; and d) cooling the once-coated granules.8. The process of claim 7, once-coated granules have a size in the rangeof 0.9 to 1.5 mm.
 9. The process of claim 7, further including, prior tostep a), preparing said core particles by granulating one or morepowdered substances containing at least one animal nutrient and abinder.
 10. The process of claim 7, wherein the first urea coatingfurther includes supplemental nitrogen, phosphorus and potassiumcompounds.
 11. The process of claim 7, wherein the urea in the firstcoating is 84.4 to 98.7%.
 12. The process of claim 7, which furtherincludes: e) spraying melted urea onto the surface of the once-coatedgranules to obtain twice-coated particles; f) granulating thetwice-coated particles to produce twice-coated granules; and g) coolingthe twice coated granules.
 13. The process of claim 12, wherein thetwice-coated core granules have a size in the range of 2.5 to 3.6 mm.14. The process of claim 13, wherein steps e) and f) are performed in afluid bed granulator.
 15. The process of claim 14, wherein the coolingof step g) is carried out in a fluid bed cooler.